EP2235088A1 - Produits en phase fondue de polyester et procédé pour leur fabrication - Google Patents

Produits en phase fondue de polyester et procédé pour leur fabrication

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Publication number
EP2235088A1
EP2235088A1 EP09703813A EP09703813A EP2235088A1 EP 2235088 A1 EP2235088 A1 EP 2235088A1 EP 09703813 A EP09703813 A EP 09703813A EP 09703813 A EP09703813 A EP 09703813A EP 2235088 A1 EP2235088 A1 EP 2235088A1
Authority
EP
European Patent Office
Prior art keywords
residues
ppm
mole
melt phase
chosen
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09703813A
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German (de)
English (en)
Other versions
EP2235088B1 (fr
Inventor
Alan Wayne White
Donna Rice Quillen
Stephen Weinhold
Barry Glen Pearcy
Jason Christopher Jenkins
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Grupo Petrotemex SA de CV
Original Assignee
Eastman Chemical Co
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Application filed by Eastman Chemical Co filed Critical Eastman Chemical Co
Priority to SI200931443A priority Critical patent/SI2235088T1/sl
Publication of EP2235088A1 publication Critical patent/EP2235088A1/fr
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Publication of EP2235088B1 publication Critical patent/EP2235088B1/fr
Priority to HRP20160610TT priority patent/HRP20160610T1/hr
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/78—Preparation processes
    • C08G63/82—Preparation processes characterised by the catalyst used
    • C08G63/84—Boron, aluminium, gallium, indium, thallium, rare-earth metals, or compounds thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/13—Phenols; Phenolates
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]

Definitions

  • the invention also relates to polyester polymers comprising at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer.
  • the invention also relates to articles comprising at least one polyester polymer melt phase product comprising at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer.
  • This invention also relates to a melt phase process for making a polyester polymer melt phase product comprising: forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts.
  • polyester compositions suitable for molding, are useful in packaging, such as in the manufacture of beverage containers.
  • PET poly(ethylene terephthalate) polymers
  • PET has become popular because of its lightness, transparency and chemical inertness.
  • PET is normally produced in a two-stage process, beginning with a melt phase stage followed by a solid stating stage.
  • the melt phase stage is typically a three-phase process.
  • ethylene glycol is reacted with terephthalic acid in a slurry under positive pressure and a temperature of 250-280 0 C yielding oligomeric PET.
  • the oligomer is heated to a slightly higher temperature, usually 260-290 0 C, and the positive pressure is changed to a mild vacuum, usually 20-100 mm, to yield the prepolymer.
  • the prepolymer is converted to the final polymer by continuing to reduce the pressure to 0.5-3.0 mm and sometimes raising the temperature.
  • typically pellets at the end of the polymer stage are increased in molecular weight by a solid state process.
  • both the melt phase and solid state process stages are conducted in the presence of an antimony catalyst.
  • Antimony can be problematic, however. When it is used as a polycondensation catalyst for polyester and the polyester is molded into a bottle, for example, the bottle is generally hazy and often has a dark appearance from the antimony catalyst that is reduced to antimony metal.
  • PET that can be produced by an antimony-free melt phase only process and that possesses higher oxidative stability. Increased stability may allow drying at the higher temperatures. Additionally, it may eliminate the need to produce higher molecular weight PET to compensate for molecular weight breakdown.
  • polyester polymers comprising at least one polyester polymer melt phase product comprising at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer, as well as articles comprising such polyester polymers.
  • This invention also relates to a melt phase process for making a polyester polymer melt phase product comprising: forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts.
  • Fig. 1 depicts the stability of PET in air at 192 0 C over the course of 24 hours from Example 1 , comparing PET and PET which was prepared with Irganox 1010 (941 ppm) added prior to the esterification process.
  • Fig. 2 depicts the stability of PET in air at 192 0 C over the course of 24 hours from Example 1, comparing PET and PET which was prepared with Irganox 1010 (948 ppm) added prior to the esterification process.
  • FIG. 3 depicts the stability of PET in air at 192 0 C over the course of 24 hours from Example 2, comparing PET and PET which was prepared with Irganox 1010 (1400 ppm) in a continuous process.
  • Fig. 4 depicts the stability of PET in air at 192 0 C over the course of 24 hours from Example 2, comparing PET which was prepared with varying levels of Irganox 1010 in a continuous process.
  • Fig. 5 depicts the stability of PET in air at 192 0 C over the course of 24 hours from Example 3, comparing PET and PET which was prepared with varying levels of Irganox 1010 added at the prepolymer stage.
  • Fig. 6 depicts the stability of PET in air at 192°C over the course of 24 hours from Example 4, comparing PET and PET which was prepared with varying levels of Irganox 1010 added at the end of the polymerization stage.
  • Fig. 7 depicts the stability of PET in air at 192°C over the course of 24 hours from Example 5, comparing PET and PET which was prepared with nonylphenol, BHT or vitamin E in a continuous process.
  • Expressing a range includes all integers and fractions thereof within the range.
  • Expressing a temperature or a temperature range in a process, or of a reaction mixture, or of a melt or applied to a melt, or of a polymer or applied polymer means in all cases that the reaction conditions are set to the specified temperature or any temperature, continuous or intermittently, within the range; and that the reaction mixture, melt, or polymer are subjected to the specific temperature.
  • a "melt phase product” is a polyester polymer obtained from a melt phase reaction.
  • Melt phase products may be isolated in the form of pellets or chips, or may be fed as a melt directly from the melt phase finishers into extruders and directed into molds for making shaped articles such as bottle preforms (e.g. "melt to mold” or “melt to preform”).
  • the melt phase product may take any shape or form, including amorphous pellets, crystallized pellets, solid stated pellets, preforms, sheets, bottles, tray, jar, and so forth.
  • melt phase product in the context of melt phase product is a broad umbrella term referring to a stream undergoing reaction at any point in the melt phase for making a polyester polymer, and includes the stream in esterification phase even though the viscosity of this stream is typically not meaningful, and also includes the stream in the polycondensation phase including the prepolymer and finishing phases, between each phase, and up to the point where the melt is solidified, and excludes a polyester product undergoing an increase in molecular weight in the solid state.
  • alkali metal refers to any metal in group IA of the periodic chart and in particular refers to lithium, sodium, and potassium.
  • alkali metal-aluminum catalyst refers to any compound that contains both an alkali metal and aluminum that is effective for catalyzing a polyester reaction or any combination of an alkali metal compound and aluminum compound that is an effective catalyst. For example, this would include, but not be limited to, a combination of lithium hydroxide and aluminum isopropoxide as well as a combination of sodium hydroxide and aluminum acetate.
  • Inherent viscosity (IV) is calculated from the measured solution viscosity. The following equations describe these solution viscosity measurements:
  • L*, a*, and b* color coordinates are measured on transparent injection- molded disks, according to the following method.
  • a Mini-Jector model 55-1 is used to mold a circular disk which has a diameter of 40 mm and a thickness of 2.5 mm. Before molding, the pellets are dried for at least 120 minutes and no more than 150 minutes in a forced air mechanical convection oven set at 170 0 C.
  • the color of the transparent injection-molded disk is measured using a HunterLab UltraScan XE® spectrophotometer.
  • the HunterLab UltraScan XE® spectrophotometer is operated using a D65 illuminant light source with a 10° observation angle and integrating sphere geometry.
  • the HunterLab UltraScan XE® spectrophotometer is zeroed, standardized, UV calibrated, and verified in control.
  • the color measurement is made in the total transition (TTRAN) mode.
  • the L* value indicates the transmission/opacity of the sample.
  • the "a*" value indicates the redness (+)/greenness (-) of the sample.
  • the "b* value indicates the yellowness (+)/blueness (-) of the sample.
  • color values are measured on crystallized polyester pellets or crystallized polymer ground to a powder passing a 3 mm screen.
  • the polyester pellets or polymer specimens which are ground to a powder have a minimum degree of crystallinity of 15%.
  • the HunterLab UltraScan XE® spectrophotometer is operated using a D65 illuminant light source with a 10° observation angle and integrating sphere geometry.
  • the HunterLab UltraScan XE® spectrophotometer is zeroed, standardized, UV calibrated, and verified in control.
  • the color measurement is made in the reflectance (RSFN) mode.
  • the results are expressed in the CIE 1976 L*, a*, b* (CIELAB) color scale.
  • the "L*" value indicates the lightness/darkness of the sample.
  • the "a*” indicates the redness (+)/greenness (-) of the sample.
  • the "b*” indicates the yellowness (+)/blueness (-) of the sample.
  • the at least one polyester polymer and polyester polymer melt phase products of the present invention comprises at least one polyethylene terephthalate polyester.
  • the at least one polyethylene terephthalate polyester is virgin (e.g., non-recycled) polyethylene terephthalate polyester.
  • the at least one polyethylene terephthalate polyester does not comprise any post- consumer recycled polyethylene terephthalate.
  • the at least one polyethylene terephthalate polyester does not comprise any pre-consumer recycled polyethylene terephthalate.
  • the at least one polyethylene terephthalate polyester comprises:
  • the at least one polyethylene terephthalate polyester further comprises up to 10 mole% of residues chosen from residues of isophthalic acid, residues of naphthalene dicarboxylic acid, residues of diethylene glycol, residues of 1,4-cyclohexanediol (CHDM), and residues of derivatives thereof.
  • Non-limiting exemplary ranges for residues of isophthalic acid are 0.5-5.0 mole% relative to the total diacid components, for residues of diethylene glycol are 0.5-4.0 wt% based on the weight of the polymer, and for residues CHDM are 0.5-4.0 mole % relative to glycol components.
  • the polyester polymer further comprises residues of phosphoric acid.
  • the at least one alkali metal-aluminum compound is lithium-aluminum.
  • the amount of the at least one alkali metal- aluminum compound present in the polymer ranges from 3 ppm to 60 ppm based on the weight of aluminum contained in the compound. In an embodiment, the amount of the at least one alkali metal-aluminum compound present in the polymer ranges from 3 ppm to 100 ppm based on the weight of the aluminum contained in the compound. In an embodiment, the amount of the at least one alkali metal-aluminum compound present in the polymer ranges from 3 ppm to 20 ppm based on the amount of alkali metal.
  • the at least one catalyst may be chosen from alkali metal-aluminum catalysts.
  • the at least one alkali-aluminum catalyst is lithium-aluminum.
  • the amount of the at least one alkali-aluminum catalyst present in the polymer ranges from 3 ppm to 60 ppm based on the weight of aluminum contained in the catalyst. In an embodiment, the amount of the at least one alkali-aluminum catalyst present in the polymer in ranges from 3 ppm to 100 ppm based on the weight of the aluminum contained in the catalyst. In an embodiment, the amount of the at least one alkali metal-aluminum catalyst present in the polymer ranges from 3 ppm to 20 ppm based on the amount of alkali metal.
  • the invention comprises at least one phenolic stabilizer.
  • the at least one phenolic stabilizer may react when added to the system. Accordingly, as used herein, the term "at least one phenolic stabilizer" encompasses both the starting stabilizer that is added to the system as well as any residues and/or reaction products of the starting stabilizer.
  • the at least one phenolic stabilizer should be of sufficient molecular weight so as to not be removed from the polymer production process.
  • the at least one phenolic stabilizer is chosen from phenolic stabilizers having a high molecular weight, such as nonylphenol.
  • suitable at least one phenolic stabilizers include pentaerythritol tetrakis[3-(3,5-di-tert- butyl-4-hydroxyphenyl)propionate] (e.g., Irganox 1010; CAS Registry No. 6683-19- 8), calcium (3,5-di-tert-butyl-4-hydroxybenzyl monoethyl phosphonate) (CAS Registry No.
  • the at least one phenolic stabilizer is chosen from phenolic stabilizers that are sterically crowded near the phenolic group, such as butylated hydroxytoluene (2,6-di-/er/-butyl-4-methylphenol) (BHT).
  • BHT butylated hydroxytoluene
  • the at least one phenolic stabilizer is chosen from phenolic stabilizers containing at least two phenolic hydroxyl groups.
  • the at least one phenolic stabilizer is pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate] (e.g., Irganox 1010; CAS Registry No.
  • the at least one phenolic stabilizer is present in an amount ranging from 5 ppm to 800 ppm. In an embodiment, the at least one phenolic stabilizer is present in an amount ranging from 20 ppm to 400 ppm. In an embodiment, the at least one phenolic stabilizer is present in an amount ranging from 150 ppm to 350 ppm. In an embodiment, the at least one phenolic stabilizer is present in an amount ranging from 200 ppm to 300 ppm. In an embodiment, the at least one phenolic stabilizer is present in an amount ranging from 225 ppm to 275 ppm. In an embodiment, the at least one phenolic stabilizer is present in an amount ranging from 100 ppm to 200 ppm. In an embodiment, the at least one phenolic stabilizer is present in an amount ranging from 5 ppm to 100 ppm.
  • the amount of the at least one phenolic stabilizer in PET may be measured in the following manner, as exemplified for the case when the at least one phenolic stabilizer is Irganox 1010.
  • Approximately 0.12 g of the PET sample is weighed into a 20-mL headspace vial with a disposable stir bar.
  • 3 mL of nPrOH with approximately 1000 ppm nonanol is weighed into the vial, and 1.5 mL of tetrabutyl ammonium hydroxide solution (60% in water) is added.
  • the vial is capped and placed into a heat/stir block at 125°C until the sample has been completely hydrolyzed, which is generally about 15 minutes.
  • the Irganox 1010 falls apart in the hydrolysis, and the alkyl portion of the molecule (pentaerythritol) is measured.
  • the mass spectrometer an Agilent 5973N, is set to monitor ions 147 and 191 when the sample is injected, the largest two ions for pentaerythritol.
  • the Agilent 5890 GC has a DB-17 capillary column which separates the components in the sample then introduces them into the mass spectrometer. The standards are run first and a calibration curve generated from those results. The area of the pentaerythritol is then calculated with the linear equation to determine the weight percent of the Irganox 1010 in the sample.
  • the at least one phenolic stabilizer may be incorporated at any point or points during the melt phase process from the formation of the slurry of at least ethylene glycol (EG) and terephthalic acid (TPA) to just before peptization.
  • the at least one phenolic stabilizer may be added to the entire process stream and/or may be added at a higher concentration to a slip stream and then mixed back with the entire process stream to achieve the desired level of stabilizer.
  • the at least one phenolic stabilizer is added in a slurry comprising ethylene glycol and terephthalic acid.
  • a polyester polymer that comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer.
  • the at least one polyethylene terephthalate polyester is virgin (non-recycled, pre- and/or post-consumer) polyethylene terephthalate polyester.
  • an article comprising at least one polyester polymer comprising at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer.
  • the at least one polyester polymer is at least one polyester polymer melt phase product.
  • the article may be a bottle, a preform, ajar, or a tray.
  • the article in an embodiment, comprises virgin (non-recycled, pre- and/or post- consumer) polyethylene terephthalate polyester.
  • a polyester polymer provided that comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer, wherein said at least one polyethylene terephthalate polyester comprises residues of at least one carboxylic acid component wherein at least 90 mole% of those residues are residues of terephthalic acid based on 100 mole% of the residues of at least one carboxylic acid component, and residues of at least one hydroxyl component wherein at least 90 mole% of the residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxyl component.
  • a polyester polymer comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer, wherein said at least one polyethylene terephthalate polyester comprises residues of at least one carboxylic acid component wherein at least 90 mole% of those residues are residues of terephthalic acid based on 100 mole% of the residues of at least one carboxylic acid component, and residues of at least one hydroxyl component wherein at least 90 mole% of those residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxyl component, and wherein said at least one polyethylene terephthalate polyester further comprises up to 10 mole% of residues chosen from residues of isophthalic acid, residues of naphthalene dicarboxylic acid, residues of diethylene glycol, residues of 1,4-cyclohe
  • a polyester polymer comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer, wherein said at least one phenolic stabilizer is chosen from nonylphenol, pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], and butylated hydroxytoluene (2,6-di-t ⁇ r/-butyl-4-methylphenol).
  • a polyester polymer comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 20 ppm to 400 ppm of at least one phenolic stabilizer.
  • said at least one phenolic stabilizer is present in an amount ranging from 50 ppm to 250 ppm.
  • a polyester polymer comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound chosen from lithium-aluminum compounds; and from 5 ppm to 800 ppm of at least one phenolic stabilizer.
  • a polyester polymer comprises at least one polyethylene terephthalate polyester; at least one alkali metal-aluminum compound; and from 5 ppm to 800 ppm of at least one phenolic stabilizer, wherein said polyester polymer does not comprise antimony.
  • said polyester polymer does not comprise titanium.
  • said polyester polymer does not comprise manganese.
  • said polyester polymer does not comprise a phosphite compound.
  • a polyester polymer that comprises
  • residues of at least one hydroxyl component wherein at least 90 mole% of the residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxyl component, and
  • the polyester polymer further comprises residues of phosphoric acid. In an embodiment, the polyester polymer further comprises a reheat additive.
  • a polyester polymer that comprises
  • residues of at least one hydroxyl component wherein at least 90 mole% of the residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxyl component, and
  • the polyester polymer further comprises residues of phosphoric acid. In an embodiment, the polyester polymer further comprises a reheat additive.
  • a polyester polymer that comprises
  • residues of at least one hydroxyl component wherein at least 90 mole% of the residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxyl component, and
  • the polyester polymer further comprises residues of phosphoric acid. In an embodiment, the polyester polymer further comprises a reheat additive.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts.
  • the process further comprises adding phosphoric acid.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts, wherein said at least one phenolic stabilizer is added to a process stream.
  • said at least one phenolic stabilizer is added to a slip stream.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts, wherein said process does not comprise solid state polymerization.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from lithium-aluminum catalysts.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts, wherein said polyester polymer melt phase product comprises residues of at least one carboxylic acid component wherein at least 90 mole% of those residues are residues of terephthalic acid based on 100 mole% of the residues of at least one carboxylic acid component, and residues of at least one hydroxyl component wherein at least 90 mole% of those residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxy 1 component.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali-aluminum catalysts, wherein said polyester polymer melt phase product comprises residues of at least one carboxylic acid component wherein at least 90 mole% of the residues are residues of terephthalic acid based on 100 mole% of the residues of at least one carboxylic acid component, and residues of at least one hydroxyl component wherein at least 90 mole% of the residues are residues of ethylene glycol, based on 100 mole% of the residues of at least one hydroxyl component, and wherein said
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts, wherein said at least one phenolic stabilizer is chosen from nonylphenol, pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4- hydroxyphenyl)propionate], and butylated hydroxytoluene (2,6-di-ter?-butyl-4- methylphenol).
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding from 20 ppm to 400 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts.
  • from 50 ppm to 250 ppm of said at least one phenolic stabilizer is added.
  • from 100 ppm to 200 ppm of said at least one phenolic stabilizer is added.
  • from 5 ppm to 100 ppm of said at least one phenolic stabilizer is added.
  • a melt phase process for making a polyester polymer melt phase product comprising forming a slurry comprising at least one glycol chosen from ethylene glycol and derivatives of ethylene glycol and at least one acid chosen from terephthalic acid and derivatives of terephthalic acid; adding 5 ppm to 800 ppm of at least one phenolic stabilizer; and reacting said at least one glycol and said at least one acid in the presence of at least one catalyst chosen from alkali metal-aluminum catalysts, wherein said polyester polymer melt phase product does not comprise antimony.
  • said polyester polymer melt phase product does not comprise titanium.
  • said polyester polymer melt phase product does not comprise manganese.
  • said polyester polymer melt phase product does not comprise a phosphite compound.
  • Example 1 Stabilizer Added at the Beginning in a Laboratory
  • Synthesis of PET in the laboratory consists of two steps: esterification of terephthalic acid (TPA) and isophthalic acid (IPA) with ethylene glycol (EG) in a Parr high pressure reactor; and polymerization of the resulting oligomer.
  • TPA terephthalic acid
  • IPA isophthalic acid
  • EG ethylene glycol
  • Step 1) Esterification: A two liter reaction vessel constructed of stainless steel was charged with TPA, IPA (2 mole % relative to PTA) and EG, and purged with nitrogen. Trimethyl ammonium hydroxide was added as a diethylene glycol (DEG) suppressant.
  • DEG diethylene glycol
  • the heating, agitation, and pressure were all controlled by a distributed control system.
  • the vessel was then heated to 245°C with constant agitation under 40 psi of nitrogen.
  • water was removed from the reactor and was collected in a receiving flask. The extent of the reaction was monitored by the mass of water removed.
  • Step 2) Polymerization Solid oligomer (113 g) was broken up and charged to a 500 mL round bottom flask along with the catalyst (0.40 g of a solution containing LiOH (2250 ppm Li) and aluminum isopropoxide (3000 ppm Al) in EG). The flask was fitted with a stainless steel paddle stirrer and the reaction was begun according to the parameters listed in Table 4 below. The temperature, vacuum, and stirring agitation were all controlled by a distributed control system. Phosphoric acid (20 mg) was added at the end of the polymerization (see Table 4, process stage 9).
  • Fig. 1 shows the difference between IV of Control B compared to Sample B over 24 hours.
  • Fig. 2 shows the difference between IV of Control C compared to Sample C over 24 hours.
  • Example 2 Stabilizer Added after Esterification in a Continuous
  • Irganox 1010 was added to a continuous TPA-based polymerization process.
  • the Irganox 1010 was added as a slurry in ethylene glycol at a process point between esterification and prepolymerization.
  • the target level of Irganox 1010 was 1400 ppm.
  • the molar ratio of the slurry of TPA/IPA/EG was 1.0/0.02/1.5.
  • the esterification was conducted at 27O 0 C and 25 psig.
  • the prepolymerization was conducted in two stages from 275 to 285 0 C and from a slight positive pressure to about 100 mm vacuum.
  • the final polymerization was conducted at 280-290 0 C at about 2 mm vacuum.
  • Phosphoric acid 50 ppm as P
  • the IV of the resulting PET was 0.80 dL/g.
  • Fig. 3 shows the differences in IV between a control made by the same process and having the same composition (although starting IV 0.73 dL/g for the control sample) as sample but without Irganox and the sample containing 1400 ppm Irganox 1010 over 24 hours.
  • Example 3 Stabilizer Added in the Middle Phase
  • PET oligomer was prepared as described for Control A in Example 1, Tables 1 and 2.
  • the oligomer (102.9 g) was then placed in a 500 mL round bottom flask equipped with a nitrogen inlet and mechanical stirrer.
  • a lithium-aluminum catalyst mixture (0.40 g of a solution containing LiOH (2300 ppm Li) and aluminum isopropoxide (3000 ppm Al) in ethylene glycol) and 0.12 g Irganox 1010 were added to the flask. All polymerizations were conducted using a distributed control system under the conditions shown in Table 6 below.
  • Target levels for the finished polymer were 9 ppm Li, 12 ppm Al, and 1200 ppm Irganox 1010 (Sample D).
  • a second polymerization was conducted under the same conditions except that phosphoric acid was added near the end of polymerization (Table 6, stage 10) at a target level of 100 ppm (Sample E).
  • a third polymerization was completed in which Irganox 1010 was added to the oligomer and was targeted at 800 ppm, and the phosphoric acid was added near the end of polymerization (Table 6, stage 10) and had a P target level of 40 ppm (Sample F).
  • the flask and contents Prior to each polymerization, the flask and contents were purged with nitrogen. A steady sweep of nitrogen at 0.4 scfh was maintained over the contents during the 10 minute melting phase prior to applying vacuum.
  • the polymer was subsequently ground and submitted for analytical testing. Data for the resulting PET polymers are shown in Tables 7-10. Haze levels in PET were measured using a Hach Ratio Turbidimeter. The haze was measured by nephelometry. A 2.3 gram sample was dissolved into 30 mL of a solvent (30% hexafluoroisopropanol, 70% methylene chloride) and placed in a 8 dram vial. The vial was capped and spun on a spinning wheel to stir for 24 hr. The solution in the vial was then read directly in the Hach Ratio Turbidimeter. A beam of light was directed through a test sample.
  • Detectors were placed to measure the 90-degree light scatter, the forward scattered light and their light transmitted through the sample. By electronically conditioning the ratio of the output of the 90-degree detector to the sum of the other two detectors, excellent linearity and color rejection was attained. The design of the optical system makes stray light negligible.
  • DEG diethylene glycol
  • Fig. 5 shows the plotted IV data from Tables 8-10.
  • Example 4 Stabilizer Added at the End of the Polymerization
  • PET was produced in a continuous process as described in Example 2 under the conditions given in Example 2 but without the addition of phosphoric acid at the end of the process and without the addition of Irganox 1010.
  • Approximately 100 g of the PET was then dried thoroughly overnight under vacuum and placed in a flask under nitrogen along with the desired amount of Irganox 1010 (see Table 11).
  • the flask was equipped with a mechanical stirrer and submerged in a molten metal bath at 278 0 C.
  • the PET was allowed to melt without stirring for 45 minutes. Afterwards, slow stirring (about 10 rpm) was begun to complete the melting of the pellets.
  • Phosphoric acid (0.008 g in Sample G and 0.016g in Sample H) was added when melting was complete.
  • the stir speed was gradually increased to 30 rpm over a 5-minute period and stirring was continued for 10 minutes. Samples of the resulting blends were ground and submitted for analysis. The results are located in Tables 11-
  • Fig. 6 shows the plotted IV data from Tables 12-13.
  • Phenolic compounds other than Irganox 1010 have been shown to stabilize PET to molecular weight degradation. These compounds were tested by blending the PET produced in a continuous phase process as described in Example 2, but without phosphoric acid being added late in the process and without Irganox 1010. BHT (2,6-di-terf-butyl-4-methylphenol), vitamin E and nonylphenol were blended using the following procedure: PET (100 g) was dried for 24 hours at 1 1O 0 C under vacuum, melted for 50 minutes at 278 0 C and then blended separately with BHT, vitamin E and nonylphenol for 10 minutes at 30 rpm in a round bottom flask. All of these compounds showed the ability to dramatically reduce molecular weight loss in PET in air at 192 0 C, as illustrated in Fig. 7.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Polyesters Or Polycarbonates (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

L'invention concerne des articles comprenant au moins un produit en phase fondue de polymère de type polyester contenant au moins un polyester de type polytéréphtalate d'éthylène; au moins un composé de métal choisi parmi des composés de métal alcalin-aluminium; et de 5 ppm à 1000 ppm d'au moins un stabilisant phénolique. L'invention concerne également un procédé en phase fondue permettant de fabriquer un produit en phase fondue de polymère de type polyester et consistant à : former une suspension épaisse comprenant au moins un glycol choisi parmi l'éthylène glycol et les dérivés de l'éthylène glycol et au moins un acide choisi parmi l'acide téréphtalique et les dérivés de l'acide téréphtalique; ajouter 5 ppm à 1000 ppm d'au moins un stabilisant phénolique; et faire réagir ledit ou lesdits glycols et ledit ou lesdits acides en présence d'au moins un catalyseur choisi parmi les catalyseurs de métal alcalin-aluminium.
EP09703813.7A 2008-01-22 2009-01-08 Produits en phase fondue de polyester et procédé pour leur fabrication Active EP2235088B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
SI200931443A SI2235088T1 (sl) 2008-01-22 2009-01-08 Poliestrski produkti iz taljene faze in postopek za izdelavo le-teh
HRP20160610TT HRP20160610T1 (hr) 2008-01-22 2016-06-06 Proizvodi od poliestera u fazi taline i postupci njihove proizvodnje

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/017,365 US20090186177A1 (en) 2008-01-22 2008-01-22 Polyester melt phase products and process for making the same
PCT/US2009/000103 WO2009094102A1 (fr) 2008-01-22 2009-01-08 Produits en phase fondue de polyester et procédé pour leur fabrication

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EP2235088A1 true EP2235088A1 (fr) 2010-10-06
EP2235088B1 EP2235088B1 (fr) 2016-03-30

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JP6600131B2 (ja) * 2014-02-17 2019-10-30 ユニチカ株式会社 ポリエステル樹脂組成物及びそれからなるブロー成形品
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JP2016216534A (ja) * 2015-05-14 2016-12-22 三菱瓦斯化学株式会社 ポリカーボネート樹脂組成物

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TW200942563A (en) 2009-10-16
TWI440652B (zh) 2014-06-11
SI2235088T1 (sl) 2016-07-29
ES2571213T3 (es) 2016-05-24
RU2010134908A (ru) 2012-02-27
MX2010007785A (es) 2010-08-09
MY152108A (en) 2014-08-15
BRPI0906806B1 (pt) 2019-07-02
HUE028486T2 (en) 2016-12-28
PL2235088T3 (pl) 2016-10-31
JP5319705B2 (ja) 2013-10-16
PT2235088T (pt) 2016-07-15
JP2011510154A (ja) 2011-03-31
HRP20160610T1 (hr) 2016-07-01
CN101977964A (zh) 2011-02-16
US20090186177A1 (en) 2009-07-23
WO2009094102A1 (fr) 2009-07-30
CN101977964B (zh) 2014-09-10
KR101573956B1 (ko) 2015-12-02
RU2520560C2 (ru) 2014-06-27
EP2235088B1 (fr) 2016-03-30
CA2711883A1 (fr) 2009-07-30
CA2711883C (fr) 2013-03-19
KR20100126695A (ko) 2010-12-02
BRPI0906806A2 (pt) 2015-07-14

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